CMSI Inc. TN'G DR150cc Owner`s manual

DR150cc Owner’s Manual
Rev 2006-2
A: INTRODUCTION
Thank you for purchasing a CMSI Manufactured TN’G motor scooter. CMSI has invested
over 10 years in establishing the facilities, technical infrastructure and nationwide sales and
service network that exists today as TN’G Scooters, a trademark of CMSI. TN’G
Scooters is growing rapidly due to its reputation in quality research, styling & design,
production and service.
We recommend genuine TN’G products for replacement parts and accessories as they have
been specifically designed for your scooter and manufactured to meet CMSI demanding
standards. With the intention of achieving our goal to provide complete customer support,
detailed parts catalogs are available for you to view at our web site, www.tngscooters.com.
We continuously keep a large inventory of parts and accessories in stock to support our
TN’G dealers, service centers and ultimately, TN’G scooter owners. Your local TN’G
dealer knows your scooter the best and always is interested in your satisfaction! We advise
your local TNG dealer make all repairs on your scooter. You can find a complete list of
dealers and service centers on our website.
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This Owner’s Manual contains important information on safety, operation, and maintenance.
Anyone who operates a TN’G Scooter should carefully read and understand the contents of this
manual before use.
TN’G Scooters are street legal vehicles in all 50 states. You need to check with your state
requirements on license and registration to ride this scooter legally on public roads.
SPECIAL SYMBOLS
Significant safety messages are provided both in this manual and on the scooter. For your safety
and the safety of others please pay special attention to all warnings preceded by !.
! WARNING - Indicates risk of severe injury or DEATH may result to the scooter operator, a
bystander or a person inspecting or repairing the scooter if failure to follow these instructions.
CAUTION - Indicates that special precaution must be taken to avoid damage to the scooter.
NOTE - A NOTE provides key information to make procedures easier to spot.
3
This Owner Manual should be considered as a permanent part of the scooter as it contains
important information for operation and maintenance of the scooter. It should remain with the
scooter at all times.
This Owner Manual contains the most current product information at the time of approval for
printing. TN’G Scooters reserves the right to make changes at any time without notice and
without incurring any obligation. If you have any questions about the manual, please consult
your TN’G dealers, or our web site www.tngscooters.com. The most recent documentation
will always be available on our web site.
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B: TABLE OF CONTENTS
A: INTRODUCTION.............................................................................................Page 2
B: TABLE OF CONTENTS...................................................................................Page 5
C: SAFETY INSTRUCTIONS...............................................................................Page 6
D: SPECIFICATIONS............................................................................................Page 13
E: COMPONENT DESCRIPTIONS & FUNCTIONS...........................................Page 14
F: PRE-RIDE CHECKLIST...................................................................................Page 21
G: PROPER OPERATION....................................................................................Page 24
H: ROUTINE CHECKS & MAINTENANCE.......................................................Page 30
I:
TROUBLESHOOTING......................................................................................Page 39
J: WARRANTY......................................................................................................Appendix
5
C: SAFETY INSTRUCTIONS
RIDING SCOOTERS IS FUN ONLY IF YOU PUT SAFETY AS YOUR TOP PRIORITY.
! WARNING: Before you start operating your scooter:
• Be sure you read this owner manual completely and understand all operating
features.
• Take sufficient time training with safe and proper riding technique.
• Practice until you are knowledgeable and comfortable with your scooter.
• Knowledgeable with all road signs.
! WARNING Failure to follow any SAFETY INSTRUCTION could cause severe injury
or even death to the scooter operator, passenger or a bystander.
Protective Gear
Riding a scooter leaves the rider exposed. Therefore, wearing appropriate protective gear
can prevent or diminish injuries from accidents.
1. An Approved Helmet
The majority of serious motorcycle injuries and deaths are the direct result of a head injury.
Therefore, drivers and passengers should always wear an approved helmet to prevent or
reduce the chance of head injury.
6
An approved helmet needs to:
• Meet U.S. Department of Transportation (DOT) and state standards. In addition
with labels from the Safety Helmet Council of America, the American National
Standard Institute (ANSI), or the Snell Memorial Foundation to assure the integrity
of the product.
• Fits snugly on your head.
• Have no obvious defects such as cracks, loose padding or frayed straps.
2.
•
•
3.
•
•
Eye and Face Protection
A plastic face shield can help prevent accidents by guarding the face from debris,
allowing the rider to devote full attention to the road.
Goggles can protect your eyes in the same manner. Never use eyeglasses or
sunglasses in place a face shield or goggles.
Clothing
Bright clothing should be worn by the driver so as to be easily seen by other
motorists.
Jacket and pants should cover your arms and legs completely, but not too loose to
flap in the wind or catch on the levers or wheels which could result in an accident.
7
•
•
•
Leather or heavy denim clothing is preferred as these materials help to prevent or
reduce abrasion.
Boots or shoes should be high enough to cover your ankles and sturdy enough to
provide support.
Gloves give you a better grip and help protect your hands from the elements.
Safe Riding
• Keep enough distance from the other vehicles around you as this gives you time to
react.
• Ensure that you have a driver’s license with correct classification to ride this scooter
in your state.
• Always observe the rules of the road. Observe the posted speed limit, and signal
your turns well in advance.
• Know your limits. Do not go faster then you are able to control. Always travel at a
speed that is proper for the terrain, operating conditions, and your experience.
• Always inspect your scooter each time you use it to make sure it is in safe operating
condition.
• Always follow the inspection and schedule maintenance procedures described in
this manual.
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•
•
•
•
•
Test your brakes after operation in wet conditions. If necessary, apply the brakes
several times to let friction dry out the linings.
Never attempt wheelies, jumps and other stunts, as these could cause damage to
the scooter and loss of control.
Always keep both hands on the handlebars and feet on the floor board during
operation.
Never consume alcohol or drugs before or while riding scooter.
Limit the travel distance to avoid fatigue that can affect your performance.
Being seen
Many scooter accidents are caused by car drivers who do not see scooter riders on the
road. Therefore you need to ensure to follow these guidelines:
• Wear bright clothing to increase visibility. Bright orange, yellow or green jackets or
vests and brightly colored helmet can help others see you.
• Always use turn signals when you are planning to turn or merge to main road and
turn it off after you have made your turn.
• Flash brake lights whenever you are going to slow down more quickly or where
others may not expect you are going to slow down.
• Stay out of blind spot of other motorists.
• When you come to an intersection, move to the portion of your lane that will bring
you into another driver’s field of sight at the earliest possible moment.
9
Carrying Passengers & Loading
! WARNING:
• This scooter is rated for 2 passengers; total weight of the rider and the
passenger must not exceed 330 lbs.
• Do not exceed 25 lbs of cargo.
• Any cargo should be kept in front compartment or under seat storage area.
You should avoid carrying passengers or large loads until you have gained sufficient
experience riding alone. Extra weight changes handling, stability, braking performance, turns,
acceleration and deceleration. To carry passengers safely you must:
1. Instruct the passenger before you start.
• Must wear a helmet.
• Get on the motorcycle after you have started the engine.
• Sit as far forward as possible without crowding the driver.
• Hold firmly to your waist, hips, or belt or passenger handle.
• Keep both feet on the pegs at all time, even when the motorcycle is stopped.
• Keep legs away from the muffler.
• Stay directly behind you, leaning as you lean.
• Avoid any unnecessary talking or motion.
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2. Adjust your riding technique with passenger
• Go slower
• Start slowing earlier as you approach a stop.
• Maintain a larger cushion of space ahead and to the sides.
• Wait for larger gaps when you want to cross, enter, or merge with traffic.
3. Keep the load low and distribute the load evenly. An uneven load can cause the
motorcycle to drift to one side.
Gasoline & Exhaust Fumes
! WARNING Gasoline is highly flammable and exhaust fumes are poisonous:
• Turn off engine before refueling.
• not to spill any gasoline on the engine, exhaust system or the plastic body.
• Do not refuel while smoking or near any open flame.
• Do not operate your scooter in a closed area as the exhaust fumes may cause loss
of consciousness or death within a short time.
• Do not park the scooter near any flammable source.
• If you swallow gasoline, inhale gasoline vapor or spill gasoline into your eyes, see
doctor immediately or call American Association of Poison Control Centers at 1800-222-1222 for assistance.
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•
If you spill gasoline on your clothes, change and wash the affected area immediately
with soap.
Modification
Any modifications to this scooter or removal of original equipment without approval from
TN’G Scooters may cause it to be unsafe for use and may trigger severe accident.
Modifications may also make your scooter illegal to use and will void any and all warranty
coverage.
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D: SPECIFICATIONS
Model
Model Number
Length
Width
Height
Dry Weight (No fuel)
Max. Load
Noise
Engine Type
CylinderArrangement
Displacement
Ignition
Transmission
Front Brake
Rear Brake
Tire Size (Front)
Tire Size (Rear)
Tire Pressure (Front)
Tire Pressure (Rear)
Del Rey 150
DR150T-6
76.7 inches
25.5 inches
44.5 inches
253 lbs
330 lbs
80dB(A)
Air Cooled - 4 Stroke
Single Cylinder
150cc
CDI
CVT
Disc Anti-Lock
Drum
130/60 x13
130/60 x13
32psi
32psi
Exhaust Vale Gap (Cold)
Spark Plug Type
Battery
Headlight
Brake / Tail Light
Turn Signal Lights
Fuses
Fuel Type
Fuel Capacity
Lubricating Oil
0.8 mm
NGKCR7HSA
12V 8Ah
12V / 18W
12V21/5W
12V/10W
15 Amps
90 Octane
6 L / 1.6 gals
SAE 10 W30
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E: COMPONENT DESCRIPTIONS & FUNCTIONS
1) Rear Carrier
2) Rear Light
3) Fuel Tank (under seat)
4) Seat
5) Throttle
6) Rear View Mirror
7) Brake Oil Resevoir
8) Front Box
9) Headlight
10) Exhaust Pipe
11) Drum Brake
12) Magneto
13) Passenger Footrest
14) Side Stand
15) Bag Hook
16) Disc Brake
17) Front Fender
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Controls and Instrument Panel
1) Horn Switch
2) Rear Hand Brake
3) Rear View Left Mirror
4) lnstrument Panel
5) Rear View Right Mirror
6) Front Hand Brake
7) Throttle
8) Electrical Starter Switch
1) Turning Indicator
2) Odometer
3) Speedometer
4) High Beam Indicator
5) Fuel Level Indicator
6) Alarm Indicator
7) Digital Clock
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Ignition Switch / Steering & Seat Lock
1. ON (starting): Engine can be started, electrical switches for horn,
lights, etc. can be activated, Keys can’t be removed
2. OFF (shutting down): Engine is deactivated, Lights, horn, etc. are
inoperable. Engine can’t be started. Keys can be removed
3.LOCK: Lights, horn, etc. can’t be used, Keys can be removed
CAUTION: If Ignition circuit (key or Remote) is ON when engine is not running will drain
battery and shorten battery life.
NOTE: Always turn” OFF” Remote Ignition and key Ignition when engine is not running.
! WARNING Do not change the key position while the scooter is in motion. It may result in
loss of control or an accident.
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Left Handle
1.
2.
Horn Switch Press - the switch to sound the horn
Turn Signal Switch - Slide switch left to turn left, slide switch
right to turn right and push in the switch to discontinue.
3.
Headlight Switch - High beam up position, low beam down
position.
4.
Engine Kill Switch Turn into the “X” position to shut off.
Turn into the “O “ position to start the engine.
CAUTION: Be sure to always use LO BEAM light
when facing oncoming traffic.
Right Handle
1.
2.
Electrical Starter Switch Press electrical starter switch
for a maximum of 5 seconds. If engine does not start,
try again after a gap of 30 seconds
Lights Slide switch to left up to first level and quarter’s
position lights will come on, slide once more to next level
the head lights will come on.
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Speedometer (See page 15) - Indicates the operating speed.
Odometer (See page 15)- Indicates accumulated distance.
Gas Gauge (see page 15) - Indicates the fuel Level. The needle moves towards “E” –
(empty) as the gas level is decreasing.
Throttle Control (see page 15)
• Control speed by rotating the throttle. (Right Grip)
• To accelerate speed, rotate the throttle towards you.
• To decelerate speed, rotate the throttle away from you.
Engine Stop Switch (see page 17) – Set the switch to on before starting the engine. Set the
switch to off for EMERGENCY STOP. For example, if the scooter overturns or you
cannot decrease speed with the throttle.
Rear Brake Lever/ Front Brake Lever (see page 15) - To apply rear brake, pull the left
lever towards the gradually. To apply the front brake, pull the right lever towards throttle
grip.
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CAUTION:
• Do not store anything susceptible to heat inside storage compartments.
• Do not let humidity spread from storage compartment.
• Do not put anything valuable or breakable in storage compartment.
• The compartment is not waterproof. Use plastic bags to store stuff when washing
the scooter.
Luggage
! WARNING:
• Front Compartment - Do not exceed maximum 3 lbs for cargo.
• Under Seat - Do not exceed maximum 22 lbs for cargo.
Fuel Tank Cap (see page 14 for location)
•
•
•
To remove the gas tank cap, lift the rear seat to expose the fuel cap. Turn the gas
cap ¼ counter-clockwise to remove.
Fill the tank up to the bottom of the filler tube. Do not fill past that point.
When finished filling gas tank, replace the gas cap ¼ clockwise to its locked
position. Swing seat down and make sure latch has engaged to lock the seat in
place.
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! WARNING:
• Always turn the engine off prior to refueling the scooter.
• Ensure the fuel tank cap is properly installed before riding.
• Do not overfill the tank as it may overflow when the fuel warms up and expands.
• Avoid spilling fuel on a hot engine.
CAUTION:
• Wipe off the spilled fuel immediately as fuel may deteriorate the paint on the scooter or
any plastic parts.
• Always use 90 octane gasoline or higher when refueling the scooter.
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F: PRE-RIDE CHECKLIST
1. CHECK THE FUEL LEVEL.
- Check the fuel gauge.
- If fuel is needed refer to directions on page 19 of this manual
NOTE: Always turn the engine off prior to refueling the scooter. Always use 90 octane gasoline or higher to refuel the scooter.
2. CHECK THE BRAKE LIGHT.
- Turn the ignition key to the “ON” position.
- Grip the front brake lever or rear brake lever while watching the rear brake light to make
sure that it illuminates.
3. CHECK THE TURN SIGNALS.
- Turn the ignition key to the “ON” position.
- Move the turn signal control to the left and right positions. Check the front and rear turn
signal lamps flash, as well as the turn signal indicators on the instrument panel.
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4. CHECK THE TIRES.
Measure the pressure in each tire. The correct pressures are:
-
Front 32 PSI
Rear 32 PSI
Visually inspect the tires for damage and wear. Look for nails, glass or stones what are
cutting into the tire casing.
Look for partial or abnormal tread wear. The middle of the tread should have:
Front Tire
1.5 mm minimum tread depth
Rear Tire
2 mm minimum tread depth
CAUTION: This Scooter uses tubeless tires on the front and rear wheels. These tires must
always be replaced with tires of the same type.
5. CHECK THE BRAKES.
Front Brake- Compress the front brake lever and measure the distance traveled before the
brake begins to slow the front wheel. The lever should travel between 10 to 20 mm before
the wheel begins to drag.
Rear Brake - Compress the rear brake lever and measure the distance travelled before
the brake begins to slow the rear wheel. The lever should travel between 10 to 20 mm
before the wheel begins to drag.
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Rear Brake Adjustment
- (See Page 31 in Section H).
Check the Brake Fluid Level.
- (See Page 31 in Section H)
6. CHECK THE SPARK PLUG
- The spark plug will need to be checked if you find the scooter hard to start. The gap should
be between 0.023 & 0.032 inches. The electrode should be a light brown color.
- Incorrect gap can cause many problems for the scooter engine. Make sure it is correct!
- If the spark plug is fouled or damaged, replace it with another of similar type.
Replacing the spark Plug.
CAUTION: Allow the engine to cool down before attempting to replace the spark plug
- (For replacement instructions see pages 32 in the Section H.)
7. CHECK THE ENGINE OIL
- (See Page 33 in Section H)
8. CHECK THE TRANSMISSION OIL
- (See Pages 34 in Section H)
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G: PROPER OPERATIONS & TECHNIQUES
! WARNING:
• Be sure you have read this owner manual completely and understand all operating
features.
• Do not start the engine or operate the scooter in closed areas , as the exhaust fumes
are poisonous and inhaling them can cause loss of consciousness and /or even
death shortly.
• This scooter is rated for two persons, total weight with rider and passenger must not
exceed 330 lbs.
1.
ENGINE STARTING PROCEDURE
NOTE: If side kick stand is down, vehicle will not start.
• Normal Start - Place scooter on the center stand
• Turn the ignition key to the “ON” position.
• While holding brake lever, firmly push the electric start.
If the engine doesn’t start after 3 to 4 seconds, then advance throttle by 1/8 to 1/4 turns.
DO NOT OVER ADVANCE.
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NOTE:
It is recommended to always “prime” the fuel system by kick-starter when starting the
scooter in the following situation (DO NOT ADVANCE THE THROTTLE WHILE KICK
STARTING):
• Cold or wet weather
• If the fuel has run dry
• If the scooters has been stored for any length of time
• If electric start does not work
If bike does not start, please refer to trouble shooting section.
! WARNING:
Do not change the position of the ignition switch while the vehicle is in motion, only
when the vehicle has come to a complete stop.
CAUTION:
• When scooter is not running, do not leave the ignition switch in the “ON” position
for extended periods of time. The battery may become depleted to the point that the
vehicle cannot be started.
• To preserve the scooter, each starting attempt should be less than 5 seconds.
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•
To maximize the engine life, warm up the engine for 2 to 3 minutes prior to riding.
No fast acceleration when the engine is still cold.
NOTE:
The engine will not start unless either the front or rear brake is activated.
2.
RETRACTING THE STAND
Center Stand – Holding the left handle with your left hand and grasping the rear rack with
your right hand, push the scooter forward and move the stand back with your foot until the
stand retracts under the scooter.
Side Stand – Grasp the handlebars with both hands and tip the scooter upright. Move the
stand back with your foot until the stand retracts under the scooter.
! WARNING:
• Do not apply the brakes too quickly or while in a turn as this may result in loss of
traction and control.
• Wet conditions will affect braking. Give twice the normal braking distance in wet or
slippery conditions. Take extra care while riding in these conditions.
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3.
•
•
•
RIDING POSITION
Place your hands on the handlebars and step onto the scooter from the left side.
Sit down on the seat while keeping your left foot on the ground for balance.
Place your right hand on the front brake lever or left hand on rear brake lever.
4. ACCELERATION & DECELERATION
Speed can be adjusted by twisting the throttle control. Twist the throttle slowly towards
you to increase speed and twist the throttle away from you quickly to decrease speed.
5. PULLING AWAY FROM THE CURB
• Sit with a leg on each side of the scooter adjust the rear view mirrors.
• Put on your turn signal before pulling away from the curb.
• Look over both shoulders for oncoming traffic; be sure that it is safe to pull out into the
traffic.
• Release the rear brake and accelerate the scooter slowly to take off.
CAUTION:
Fast acceleration when the engine is cold can damage transmission.
6. USING THE BRAKES
• The brakes work best when the front and rear brakes are applied
simultaneously.
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CAUTION: Test your brakes after washing your scooter or riding through a
large pool of water. When this happens, apply the brakes gently until they
dry themselves and work effectively again.
7.
•
•
•
•
STOPPING & PARKING
Release the throttle and steer the scooter to the side of the road. Gently apply the
front brake with your right hand, and at the same time gently compress the rear
brake lever with your left hand.
Extend your left foot just before coming to a complete stop so as to keep the
scooter upright when it stops.
Turn off the ignition key and dismount the scooter on the left side.
Use your right foot to extend the side stand of the scooter.
! WARNING:
Do not touch the engine and the exhaust system as they can become very hot.
CAUTION:
• If the scooter will be parked for an extended period of time, use the center stand
instead.
• Do not park on a slop or soft ground as the scooter may overturn.
• Do not park near to any flammable material.
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8.
•
•
•
•
BREAK IN PROCEDURES
It is very important to follow this procedures during the first 300km to achieve the
best performance from the scooter.
Limit full throttle operation and avoid any condition that may result in engine
overheating.
Always keep the speed below 40 mph.
Do not overload the scooter or carry a passenger during this period.
CAUTION: Have your TN’G Scooter dealer check the vehicle, if any engine
trouble occurs during this period.
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H: ROUTINE CHECKS & MAINTENANCE
30
NOTE: * If regular driving is in arid or coastal condition, air filter and engine oil may need
replaced more frequently.
RECOMMENDED: To insure warranty and quality performance have a TN’G dealer
perform regular maintenance.
TIRE PRESSURE / TREAD
Measure the pressure of each tire. The correct pressures are: Front 32 PSI / Rear 32 PSI.
Visually inspect the tires for damage and wear or abnormal tread wear. Look for nails, glass,
stones or any sharp object cutting into the tire casing. The middle of the tread depth should
have: Front 1.5mm / Rear 2mm
CAUTION: This scooter uses tubeless tires on the front and rear wheels, always replaced
with tires of the same type.
REAR BRAKE ADJUSTMENT
Total free play for brake lever should not exceed 30 mm. To firm up brake, turn nut located
on the left side of the back wheel clockwise until you reach the acceptable level. Turn it
counterclockwise to soften brake.
HYDRAULIC BRAKE FLUID LEVEL - Front Brake
1. Check the fluid level by looking at the reservoir. The fluid level must be between the
two lines. If it is below the lower line, check the brake line and cylinder for a possible
leak.
31
2. Check the brakes for excessive wear. The middle groove of the brake should still be
visible. If it isn’t, the pads should be replaced.
3. To replace the brake fluid, open the reservoir and add fluid as required.
CAUTION:
•
•
•
Be sure not to introduce any water or air into the brake system when changing
the fluid.
Do not spill any brake fluid on any other motorcycle parts as the fluid can
damage metal and paint.
Always replace the brake fluid with type DOT 3 brake fluid.
RECOMMENDATION: An authorized TN’G Dealer or Service Center should complete all
brake fluid adjustments.
SPARK PLUG REPLACEMENT
Check spark plug if scooter is hard to start.
1. The gap should be between 0.023 & 0.032 inches.
2. The electrode should be a light brown color.
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3. Replacing the spark plug,
• Remove the plug cover and remove the spark plug using the spark plug
wrench in the tool kit.
• After setting the gap of the new plug, insert it into the cylinder & tighten
firmly by hand, then by using provided wrench tighten another ½ to ¾ turns.
• Reattach the spark plug cover.
! WARNING: Do not change spark plug while engine is hot.
CAUTION:
• Incorrect gap can cause problems to the scooter engine. Make sure it is correct!
• If the spark plug is fouled or damaged, replace it with (NGKCR7HSA) or like plug.
RECOMMENDATION:
Most spark plugs are self-cleaning. After replacing its best to ride the scooter for a
minimum of 10 min.
CHECKING ENGINE OIL LEVEL
When the scooter is new, the oil will need to be changed after the first 300 Km. (please
review regular maintenance schedule on page 30) The oil level should be checked every
500 km and oil added as needed.
1. Stop the scooter on a level surface and turn the engine off.
33
2. Put the scooter on its center stand and let the engine sit for a few minutes.
3. Remove the oil dipstick, wipe it with a clean towel and replace it. Just rest the
dipstick on the threads, do not screw it down into place when measuring the oil
level.
4. Remove the dipstick again and observe the oil level. It should be between hi and
low-level marks on the dipstick.
5. If the oil level is near the low mark, please add enough SAE 10W30 lubricating oil
to bring the level up near hi mark.
CAUTION: If the scooter is being used under more severe conditions such as gravel roads
or lots of stop & go traffic, then the oil should be changed more frequently than every 4000
km.
CHECK THE TRANSMISSION OIL
Inspect the transmission oil after the first 300 km and then after every 4000 km or six
months which ever comes first.
NOTE: Recommend use SAE 10W40 oil in the transmission.
1. Place the scooter on its center stand on a level surface. Let the engine warm up for
three minutes and then shut the engine off.
2. Remove the oil fill plug and the oil drain plug and allow the oil to drain completely.
3. Inspect the sealing washer on the drain plug, and if it’s OK reinstall the drain plug.
34
4. Refill the gearbox until full.
5. Reinstall the oil fill plug.
! WARNING: Use caution when changing oil to avoid burns!
CAUTION:
• If the scooter is used in excessively wet areas, or used in severe conditions replace
the transmission oil more often than recommended.
• Make sure that the fill and drain plugs are tight and not leaking.
• Make sure that no foreign substances fall into the transmission box.
AIR FILTER MAINTENANCE
The air filter should be inspected and cleaned at every 1000km interval.
1. Lift seat up, air box is located in front of seat compartment.
2. Remove the screws that hold the cover of the air cleaner in place and lift off the air
cleaner cover.
3. Lift out the air filter screen and cartridge.
4. Clean the screen and cartridge with compressed air.
5. Replace the cartridge if neccessary.
6. Reassemble the air filter components and back end of the scooter.
35
CAUTION:
•
If riding in an excessively dusty location, the air filter should be inspected
more often than the recommended.
• When remounting the air cleaner cover components onto the scooter. Be
careful to fit all pieces into their correct place. Failure to achieve proper fit
will cause leaks in the air intake system that can cause engine damage.
• Handle the air filter cartridge carefully so that it does not become deformed.
• Never allow water to enter the air filter assembly.
NOTE: Clean and/or replace the air filter components if you experience a decrease of
engine power.
BATTERY MAINTENANCE
Your Scooter uses a calcium sealed, maintenance free, VRLA battery and you should not
remove the sealing strip once the battery has been installed and prepped by a TN’G dealer.
NOTE: To protect your battery against failure it is important to keep your battery fully
charged. This applies primarily if you are not riding your scooter on a regular basis or are
traveling only short distances while you ride. In these limited use situations you should
charge your battery at least once a month using the included battery charger for a minimum
36
of 10 hours. Additionally, it is important that your scooter be stored in a dry area and
protected from extreme temperatures.
BATTERY REPLACEMENT
The scooter battery is self-sustained by electric current generated by the alternator within
the scooter. It’s a good idea to replace the battery every three years.
1. Always turn the ignition system off prior to replacing the battery.
2. Observe correct polarity when replacing the battery. The RED wire is connected
to the positive battery terminal and the BLACK wire is connected to the negative
battery terminal.
3. Make sure that the battery posts are kept clean at all times and have good contact
area. Use a wire brush to remove any signs of corrosion if required.
4. Avoid sparks or flame when handling the battery.
FUSE REPLACEMENT
Main Fuse
1. The main fuse is located next to the battery in the floorboard; it is rated at 15 Amps.
2. A visual inspection of the fuse will tell if the fuse is “open” (burned out).
3. If the fuse is open, then it needs replacement.
NOTE: Check fuse for good tight contact within fuse housing.
37
! WARNING: Always turn the ignition off before inspecting the fuses.
CAUTION:
• When removing the fuse from the fuse box do not squeeze the fuse puller or it will
release the fuse.
• When inserting the new fuse be sure that it fits snugly into the fuse socket. A loose fit
will cause intermittent electrical problems and possible overheating of the fuse
contacts.
• Always replace the open fuse with another of the same type!
• When washing your scooter, be sure not to get water into the fuse box as this could
cause electrical problem.
• Do not use a fuse of higher amperage than recommended; this will cause extensive
damage to the electrical system and possibly a fire.
NOTE: If the new fuse burns out immediately, have a TN’G dealer check scooters
complete electrical system.
38
I: TROUBLESHOOTING
ENGINE IS DIFFICULT TO START
1. Check for Fuel in Carburetor
i. If No Fuel
a. Out of gas – Fill fuel tank
b. Fuel cap air hole blocked – Unblock air hole
c. Fuel filter or petcock blocked – Clean or replace
fuel switch
ii. With Fuel – Check Spark Plug
2. Check Compression
i. No Compression – Have TN’G dealer inspect the scooter
ii. With Compression – Check Spark Plug
3. Spark Plug
i. No Spark
a. Spark plug wet or fouled – Remove plug & prime
kick the start pedal without fuel & ignition. Reinstall spark plug
b. Intermittent spark plug lead – Replace lead
c. Spark plug dirty or wrong gap – Replace plug or
correct gap
39
d. Loose spark plug – Tighten spark plug
ii. Spark Plug OK – Check Carburetor
4. Carburetor
i. Carburetor Defective
a. Blocked idle jet – Clean jet
b. Dirty float bowl – Clean bowl
c. Low fuel in bowl – Adjust bowl
ii. Carburetor OK
a. Engine overheated – Check & replace lubricating
oil
b. Air inlet system blocked or leaky – Remove
blockage or leak
KNOCKING SOUND IN CYLINDER
Causes
Solutions
1. Engine Overheating
Check & replace lubricating oil
2. Spark Plug Defective
Replace the spark plug
3. Ignition Timing Too Early
Adjust ignition timing
4. Carbon Build-Up
i. In Cylinder
Remove carbon build-up
ii. In Exhaust Pipe & Muffler
Remove carbon build-up
40
LOW POWER OUTPUT FROM ENGINE
Causes
1. Air Cleaner Blocked
2. Fuel Line In Carburetor Blocked
3. Excessive Carbon Deposit On Piston
In Cylinder & Exhaust System
4. Piston & Cylinder Excessively Worn
5. Ignition Timing Incorrect
6. Clutch Slipped
7. Belt Is Lose
Solutions
Clean Air Filter
Remove Residue
Remove Carbon Build-Up
Replace Piston & Cylinder
Adjust Timing
Adjust Clutch
Replace Belt
BLACK OIL & EXHAUST FROM EXHAUST PIPE
Causes
Solutions
1. Carburetor Not Atomizing Fuel Properly
Check & Adjust Carburetor
2. Air Cleaner Blocked
Clean Air Filter
41
POOR FUEL ECONOMY
Causes
1. Fuel System Leaks
2. Air Cleaner Blocked
3. Idle Speed Too High
4. Riding At Excessive Speeds
Solutions
Repair Leak
Clean Air Filter
Adjust Idle Speed
Ride At More Economical Speeds
FUEL DRAINING FROM CARBURETOR OVERFLOW TUBE
Causes
Solutions
1. Float Bowl Residue
Clean The Float Bowl
2. Float Bowl Needle Valve Not
Replace Needle Valve
Completely Closed
3. Occasional Fuel Overflow
Tap The Fuel Bowl Lightly
PETCOCK / FUEL FILTER LEAKS
Causes
1. Fuel Switch Loose
2. Broken Seal
Solutions
Tighten The Fuel Switch
Replace Fuel Switch
42
WARRANTY
CMSI, Inc., warrants to the first retail purchaser of all TN’G vehicles from an Authorized CMSI
Dealer and each subsequent owner that the vehicle is free from defects in materials and workmanship for the period stated in this warranty section.
To Qualify For This Warranty
• The CMSI vehicles must be purchased from a dealer within the United States,
Canada or Mexico who is authorized by CMSI to sell CMSI products.
• Dealer must be signed up and be familiar with CMSI warranty policy.
Warranty Verification Method
Owner and dealer sign Owner Registration Card at time of purchase. This information is kept in
CMSI’s warranty system and can be requested thru an authorized dealer.
1
WARRANTY RESPONSIBILITY
The Manufacturer
CMSI Inc.
To repair or replace , at its option, any part which is proven to be defective in material or factory
workmanship under normal use for the applicable warranty period.
• The repair or replacement of defective parts under this limited warranty must be made by
an Authorized CMSI Dealer or service center. Warranty repairs will be made at no charge
to you for parts or labor.
• Parts repaired or replaced under warranty are warranted only during the balance of the
applicable warranty period.
The Authorized Dealer
To give you complete warranty documentation when you pick up your vehicle. To perform warranty
repairs on any CMSI product that qualifies for such repairs.
The selling dealer shall sign the Acceptance Certificate and a Card of Delivery upon delivery of the
vehicle.The Card of Delivery outlines the steps your dealer has taken to fulfill his responsibility to
properly assemble and service your new vehicle and inform you of proper break-in, warranty,
periodic maintenance and maximum load and other riding and safety rules.
2
You, the Owner
• The customer should retain all service records for future reference.
• Service inspections and replacements in accordance with the time and mileage intervals
given in the Maintenance Schedule are essential.
• You are responsible for paying all maintenance costs, including service interval costs.
• Failures which occur due to improper maintenance as determined by T N’G are not covered
under this warranty.
• The customer may choose the extended warranty option for engines on 50cc and above
models by purchasing the Interlube Opti-4 engine lubricant at the time of purchase of the
new unit and use only that lubricant during the entire warranty period.
An authorized CMSI dealer is your best source for scheduled maintenance on your vehicle.
Regardless of who performs your maintenance, if warranty repairs are needed, your dealer may ask
you for documentation which may consist of one or more of the following:
• A Maintenance Record showing the odometer mileage and service date. Each entry should
be signed or stamped by a person who is qualified to service your motorcycle or yourself if
you have performed the maintenance.
3
•
Copies of repair orders or other receipts for required maintenance that include the odometer
mileage and service date.
NOTE: All maintenance receipts should be kept by the owner.
Warranty Coverage Table
4
Coverage Begins
The date the motorcycle is delivered to the first retail purchaser
Warranty
CMSI shall repair or replace, at its option, any part (including parts of the emission control system) that
is found defective in material or workmanship under normal use for the applicable time period.
Parts or Labor
No charge to you.
WARRANTY DISCLAIMERS, LIMITATIONS & EXCLUSIONS
Disclaimer of Consequential Damage & Limitation of Implied Warranties
CMSI Inc. disclaims any responsibility for:
• Loss of time
• Loss of use of vehicle
• Transportation expenses (rental and /or towing)
• Any other incidental or consequential damage
• Any other incidental or consequential expenses (storage)
5
Duration of Implied Warranties
Any Implied Warranties, including the implied warranty of merchantability and fitness for a particular
purpose are limited to the duration of this written warranty.
State Laws May Vary
The previously listed limitations or exclusions may not apply to a motor scooter because of state
laws. Some states may not allow limitations on how long an implied warranty lasts. Some states may
not allow exclusion or limitation of incidental or consequential damages.
Your Legal Rights
These warranties give you specific legal rights. You may also have other rights which vary from state
to state. It is the responsibility of the owner to be aware of state laws which pertain to this issue in
your particular state.
These Warranties Do Not Cover
Failures which are not due to a defect in material or factory workmanship.
Parts or accessories affected or damaged by:
• Lack of required maintenance
• Owner abuse or misuse
• Accident and/or collision
6
•
•
•
•
•
•
•
•
•
•
•
•
Normal wear
Neglect
Improper installation
Unsuitable use in an application for which the part was not designed
The incorporation or use of unsuitable attachments or parts
The unauthorized alteration of any part
The incorporation or use of unsuitable attachments or parts
Deterioration from the elements
Failure to follow “break-in” procedures
Replacement of expendable maintenance item including, but not limited to:
-Spark plug
-gaskets
-coolant
-belts
-Filters
-hoses
-lubricants
-fuses
-Tires (see Owner’s Manual)
Paint and/or decals fading, peeling, blistering, chipping or rusting.
Plastic body parts and panels, See “Warranty Time Table”
Use for the following activities, shall VOID coverage:
• Racing
• Competition
7
•
•
•
•
•
Rental or other commercial uses
Towing another vehicle, trailor or similiar device
Alteration to the engine or drive train
Any operation or use outside of that described in this Owner’s Manual
Alteration of the odometer so that the actual mileage connot be determined; alteration may
VIOD coverage
Replacement parts refer to Distributors Limited Warranties – Replacement Parts
DISTRIBUTORS LIMITED WARRANTY – NEW MOTORCYCLE
CMSI warrants to the first retail purchaser and subsequent purchasers of this vehicle that the motorcycle is free from defects in materials ands workmanship for the period stated in “Warranty Time
Table”.
To Qualify For This Warranty
•
The vehicle must originally have been purchased from a dealer within the United States,
Canada, or Mexico who is authorized by CMSI to sell CMSI products.
8
•
Prior to delivery to the purchaser, setup and pre-delivery service must be performed by a
dealer or service center who is authorized by CMSI to deliver it vehicles.
DISTRIBUTOR’S LIMITED WARRANTY- MOTORCYCLE TIRES
Warranty Time Period
90 days, or until the center tread is worn to a depth of 3/32" , whichever occurs first.
Coverage begins
• Original tire on motorcycle - date of delivery
• Tire purchased as replacement - date of purchase
Warranty Coverage
Tires distributed and sold by CMSI which are either
• Original equipment on CMSI vehicles, or
• Specified by CMSI for the model the tire is installed on and purchased from an Authorized
Dealer for replacement use.
To qualify for this warranty
• The tire must have been purchased from an Authorized CMSI Dealer.
9
•
•
The tire was part of the original factory equipment.
The tire must have been used for its designed purpose.
The Obligation of CMSI Inc
To replace any tire which is proven to be defective in material or factory workmanship under normal
use – until the tire center tread is worn to a depth of 3/32". At that point, there will be no further
warranty consideration, regardless of the tire’s age or mileage.
Your Obligation
To practice proper tire care and prudent motorcycle operation. You must maintain tire inflation
pressure and load in accordance with information in the manual, the tire information label on the
motorcycle, and restrictions molded into the tire sidewalls. The replacement of a defective tire
under this warranty must be made by an Authorized CMSI Inc Dealer.
Replacement Charges – up to 50% tread wear
Tire :No charge for a new direct replacement tire.
Labor : No charge for mounting and balancing – to the tire’s original purchaser if the tire was factory
or dealer installed.
You pay for mounting and balancing - if the tire was sold un-installed.
10
Replacement Charges – after 50% tread wear
Tire : 50% charge for a new direct replacement tire.
Labor : 50% charge for mounting and balancing.
This Warranty Does Not Cover
• Tires installed on non-CMSI vehicles
• Tires worn beyond the service limit specified in the appropriate Owners Manual.
• Tires rendered unserviceable by road hazard damage, such as impact breaks, punctures,
cuts, or snags.
• Tires rendered unserviceable by running while flat, spinning, improper inflation, overloading,
misalignment, improper mounting during replacement of after repair, or installation on
unsuitable rims.
• Tires rendered unserviceable due to abuse or misuse such as towing a trailer.
• Tube-type tires fitted without inner tubes.
• Tires which have been repaired.
• Tires whose sidewalls have been modified by the addition or removal of material.
• Tires with superficial weathering, checking, or cracking.
• Tires used in racing or other competition.
11
DISTRIBUTOR’S LIMITED WARRANTY – REPLACEMENT PARTS
Warranty Time Period: See “Warranty Coverage Table” on page 4 of Warranty Section.
Coverage begins: The date of purchase from an Authorized CMSI Dealer.
To qualify for this warranty, the genuine CMSI part
• Must have been purchased from an Authorized CMSI Dealer.
• Must have been used in an application for which it was designed.
Warranty Coverage
• CMSI Inc will repair or replace, at its option, any genuine CMSI part that is defective in
material or workmanship under normal use.
• Proof of date of purchase is required.
Parts installed by an Authorized CMSI Dealer:
Parts & Labor : No charge.
Parts not installed by an Authorized CMSI Dealer:
Parts : No charge
Labor : You pay for removal/installation charges
12
This Replacement Parts Warranty Does Not Cover
The following exclusions apply specifically to replacement parts in addition to the exclusions listed:
• Tires (Refer to Distributor’s Limited Warranty – Motorcycle Tires)
• The motorcycle in which the part is installed.
• The color match of painted components (CMSI makes no warranty , expressed or implied,
regarding the color match of painted components).
REPORTING SAFETY DEFECTS
If you believe that your vehicle has a defect which could cause an accident or could cause injury or
death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA)
in addition to notifying CMSI Inc.
If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety
defect exists in a group of vehicles, it may order a recall and remedy campaign. For this reason it is
very important for you to notify CMSI of any change of address or ownership. NHTSA cannot
become involved in individual problems between you, your dealer or CMSI.
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (or
202-366-0123 in Washington DC area) or write to :NHTSA, US Department of Transportation,
Washington DC 20590. You can also obtain other information about motor vehicle safety from the
hotline.
13
EMISSION CONTROL SYSTEM WARRANTY
US EPA
The following warranty applies to the emission control system and is in addition to the LIMITED
WARRANTY and NOISE CONTROL SYSTEM WARRANTY.
CMSI Inc. warrants to the first owner and each subsequent owner that his vehicle is designed and
built so as to conform at the time of sale with applicable regulations of the US Federal Environmental Protection Agency at the time of manufacture and that it is free from defects in materials and
workmanship which cause the motorcycle not to meet US Environmental Protection Agency Standards within the following:
If an emission-related part on your motorcycle is defective, the part will be repaired or replaced by
CMSI. This is your emission control system DEFECTS WARRANTY.
The warranty period shall begin on the date the motorcycle is delivered to the first retail purchaser
or, if the motorcycle is placed in service as a demonstrator or company vehicle prior to sale at retail,
on the date it is first placed in service.
14
The following items are not covered by the emission control system warranty:
1.
Failures which arise as as a result of misuse, alterations, accident or non-performance of
maintenance as specified in the Owners’ Manual.
2.
The replacement of parts (such as spark plugs, fuel and oil filters, etc.)
used in required maintenance.
3.
Loss of time, inconvenience, loss of motorcycle use or other
consequential damages.
4.
Any motorcycle on which the odometer mileage has been changed so that
the mileage cannot be determined.
RECOMMENDATIONS FOR REQUIRED MAINTENANCE
IT IS RECOMMENDED THAT ANY EMISSION SYSTEM MAINTENANCE BE PERFORMED BY AN AUTHORIZED CMSI DEALER USING GENUINE CMSI REPLACEMENT PARTS. THE MAINTENANCE, REPLACEMENT OR REPAIR OF THE EMISSION
CONTROL SYSTEM MAY BE PERFORMED BY ANY OTHER QUALIFIED SERVICE
OUTLET OR INDIVIDUAL. NON-GENUINE PARTS MAY BE USED ONLY IF SUCH
PARTS ARE CERTIFIED TO COMPLY WITH US ENVIRONMENTSL PROTECTION
AGENCY STANDARDS.
15
US Emission Control System (California)
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board and CMSI, Inc. (hereafter “CMSI”) are pleased to explain the
emission control system warranty on your 2005 and later motorcycle. In California new motor
vehicles must be designed, built and equipped to meet the State’s stringent anti-smog standards.
CMSI must warrant the emission control system on your motorcycle for the periods of time listed
below provided there has been no abuse, neglect or improper maintenance of your motorcycle.
Your emission control system may include parts such as the carburetor or fuel injection system,
catalytic converter and engine computer. Also included may be hoses, belts, connectors an other
emission-related assemblies.
Where a warrantable condition exists, CMSI, Inc will repair your motorcycle at no cost to you,
including diagnosis, parts and labor.
16
MANUFACTURER’S WARRANTY COVERAGE
See “Warranty Coverage Table” on page 4 of warranty section.
OWNER’S WARRANTY RESPONSIBILITIES
As the motorcycle owner, you are responsible for the performance of the
required maintenance listed in your owners’ manual. CMSI recommends that
you retain all receipts covering maintenance on your motorcycle, but CMSI
cannot deny warranty solely for the lack of receipts or for your failure to ensure
the performance of all scheduled maintenance.
You are responsible for presenting your motorcycle to a CMSI dealer as soon
as a problem exists. The warranty repairs should be completed in a reasonable
amount of time, not to exceed 30 days.
As the motorcycle owner, you should be aware that CMSI may deny your
warranty coverage if your motorcycle or a part has failed due to abuse, neglect,
improper maintenance or unapproved modifications.
If you have any questions regarding your warranty rights and responsibilities, you should contact
CMSI, Inc. P.O. Box 969, 8146 304th Ave SE, Preston, WA 98050, or the California Air Resources Board at P.O.Box 8001, 9528 Telstar Avenue, El Monte, CA 91734-8001.
17
CMSI, Inc., 8146 304th Ave SE, Preston, WA 98050, (hereinafter
“ CMSI”) warrants that each new CMSI motorcycle includes as standard equipment a headlight,
taillight and stoplight, and is street legal:
A.
B.
I.
is designed, built and equipped so as to conform at the time of initial retail purchase with
all applicable regulations of the United States Environmental Protection Agency, and the
California Air Resources Board; and
is free from defects in material and workmanship which cause such motorcycle to fail to
conform with applicable regulations of the United States Environmental Protection
Agency or the California Air Resources Board for a period of use (See Warranty Coverage Table on page 4 of warranty section).
COVERAGE. Warranty defects shall be remedied during customary business hours at
any authorized CMSI dealer located within the United States of America in compliance
with the Clean Air Act and applicable regulations of the United States Environmental
Protection Agency and the California Air Resources Board. Any part or parts replaced
under this warranty shall become the property of CMSI.
18
In the State of California only, emission related warranted parts are specifically defined by the
state’s Emission Warranty Parts List. These warranted parts are: carburetor and internal parts;
intake manifold; fuel tank; fuel injection system; spark advance mechanism; crankcase breather;
air cutoff valves; fuel tank cap for evaporative emission controlled vehicles; oil filter cap; pressure control valve; fuel/vapor separator; canister; igniters; breaker governors; ignition coils;
ignition wires; ignition points; condensers; and spark plugs if failure occurs prior to the first
scheduled replacement ; and hoses, clamps, fittings and tubing used directly in these parts.
Since emission related parts may vary from model to model, certain models may not contain all
of these parts and certain models may contain functionally equivalent parts.
In the State of California only, Emission Control System emergency repairs, as provided for in
the California Administrative Code, may be performed by other than an authorized CMSI
dealer. An emergency situation occurs when an authorized CMSI dealer is not reasonably
available, a part is not available within 30 days, or a repair is not completed within 30 days.
Any replacement part can used in an emergency repair. CMSI will reimburse the owner for the
expenses, including diagnosis, not to exceed CMSI suggested retail price for all warranted parts
replaced and labor charges based on CMSI recommended time allowance for the warranty
repair and the geographically appropriate hourly labor rate. The owner may be required to
keep receipts and failed parts in order to receive compensation.
19
II.
LIMITATIONS. This Emission Control System warranty shall not cover any of the
following:
A. Repair or replacement required as a result of
(1)
accident,
(2)
misuse,
(3)
repairs improperly performed or replacements improperly installed,
(4)
use of replacement parts or accessories not conforming to CMSI,
Inc. specifications which adversely affect performance and/or
(5)
use in competitive racing or related events.
B. Inspections, replacement of parts and other services and adjustments required for
required maintenance.
C. Any motorcycle on which the odometer mileage has been changed so that actual
mileage cannot be readily determined.
III.
LIMITED LAIBILITY
20
A. The liability of CMSI under this Emission Control System Warranty is limited solely
to the remedying of defects in material or workmanship by an authorized CMSI
motorcycle dealer at its place of business during customary business hours. This
warranty does not cover inconvenience or loss of use of the motorcycle or transportation of the motorcycle to or from the CMSI dealer. CMSI SHALL NOT
LIABLE FOR ANY OTHER EXPENSES, LOSS OR DAMAGE, EITHER
DIRECT, INCIDENTAL, CONSEQUENTIAL OR EXEMPLARY ARISING IN
CONNECTION WITH THE SALE OR USE OF OR INABILITY TO USE
THE CMSI MOTORCYCLE FOR ANY PURPOSE. SOME STATES DO
NOT ALLOW THE EXCLUSION OR LIMITATION OF ANY INCIDENTAL
OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATIONS MAY
NOT APPLY TO YOU.
B. No express emission control system warranty is give by cmsi except as specifically
set forth herein. Any emission control system warranty implied by law, including any
warranty of merchantability or fitness for a particular purpose, is limited to the
express emission control system warranty terms stated in this warranty. The forgoing statements of warranty are exclusive and in lieu of all other remedies. Some
states do not allow limitations on how long an implied warranty lasts so the above
limitations may not apply to you.
21
C. No dealer is authorized to modify this CMSI Limited Emission Control System
Warranty.
IV.
LEGAL RIGHTS. This warranty gives you specific legal rights, and you may also
have other rights, which vary from state to state.
V.
THIS WARRANTY IS IN ADDITION TO THE CMSI LIMITED MOTORCYCLE
WARRANTY.
VI.
ADDITIONAL INFORMATION. Any replacement part that is equivalent in performance and durability may be used in the performance of any maintenance or repairs. However,
CMSI is not liable for these parts. The owner is responsible for the performance of all required
maintenance. Any individual or service establishment may perform such maintenance. The
warranty period begins on the date the motorcycle is delivered to ultimate purchaser.
22
8146 304th Ave SE
Preston, WA 98050
www.cmsiinc.com
WarrantyRev2006-2